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 Optional
Customer Maintenance
Why pay big bucks for service on your
Xerox 5090 or Docutech NP-135 copiers when you can do your own
maintenance?
By Raymond
Cote
In
doing these articles on the maintenance of the Xerox 5090
copier, I was pleasantly surprised to discover that most of the
emailed questions came from the operators of the copiers. The
companies they worked for decided to repair their own equipment
and the articles I wrote on the maintenance and repair helped
them put their machine back into production and keep it there.
Increasingly I have discovered
that there are more companies out there that are servicing their
own copiers and printers because it offers them an alternative
to poor service and high costs. All too often I have heard
complaints from small- and medium-sized printers that their
service provider may make them wait long periods of time before
a technician actually walks through their front door, only to
discover that they need an exotic part that was not in stock. Or
they may complain about the high cost of doing business with a
vendor or the manufacturer.
Optional Customer Maintenance
(OCM) can save a printer about 75% of what they are now paying
for a full-service maintenance provider. Also, taken into
consideration, parts are easily obtained, and there are
companies that will offer telephone diagnostics for system
faults that are hard to resolve. In my opinion, a well-trained
customer can resolve about 93% of the machine problems they
encounter. Some 5% can be resolved with telephone diagnostics,
and the remaining 2% may require a field engineer on site.
The OCM program is becoming
quite popular with printers across the United States because it
offers them an alternative service strategy that is both
convenient and affordable. Over the last year I have had many
emails sent to me inquiring about customer training in the
“Optional Customer Maintenance” program. If you are interested
in self-maintenance, email me for additional details about the
course.
Common Docutech NP-135 system
faults
In the past we have explored
most of the common fault codes that occur in the Xerox 5090
family of copiers. Most of the system faults can be resolved
with the proper documentation and determination from the tech
that is doing the repair work. Once again, I have to state that
for best results the tech should have formal training on this
copier because of its enormous complexity. One of our biggest
mistakes is “pilot error,” and if you do not follow procedures
very closely you will always dig yourself a deeper hole. When
this happens, I always tell myself to go back to basics—in this
case, open the book and do the RAP from start. If it doesn’t fix
the problem, do all the adjustments and then start over. Most of
the information for the Xerox 5090 family can, in most cases, be
applied to the Xerox Docutech NP-135 Copier/Printer (with a few
exceptions).
I would like to thank all the
technicians and self-maintenance customers for their input and
suggestions about these system faults, and for their research
and due diligence in verifying these fixes. If you have
information to share, please submit your ideas to me via email
at VillageCopierNY@aol.com and I would be delighted to pass the
information along to the field.
In this column, I would like to
explore some common system faults that occur in the Docutech
Copier/Printer. Once again, I have to remind the reader that the
official documentation for the Docutech NP-135 is very
comprehensive and will usually lead to a completed call. If the
RAPs do not actually fix the problem try to match up the system
fault with the chart below. Good luck!
|
Fault Code |
Description of fault and
most common resolution |
|
CO2-202 |
User interface system faults
while booting from a streaming tape. It is usually caused
when the mouse or the keyboard is touched. It is critical to
remember to never touch the mouse or keyboard while using
the tape. |
|
C02-204 |
Replace filters in the UI
Power Supply |
|
C03-310 |
Replace filters in the UI
Power Supply |
|
C03-360 |
Trying to create Disk
Volumes. Use new Utility Tape |
|
C03-392 |
Rollovers in the controller.
Replace the ESS Power supply. |
|
C03-492 |
Try a Special boot, or
Restore boot. |
|
C16-201 |
“J” PWB failed (swap it with
one that you know works) |
|
C16-365 |
“H” PWB failed. (swap it
with one that you know works) |
|
C17-321 |
This fault was displayed
after a Hard Drive was replaced. Replace the “B” PWB.
|
|
C17-321 |
Intermittent or hard
failure. Reformat all hard drives and reload software.
|
|
C17-322 |
Constant “Roll over,” and
will not Boot. Replace the “P” PWB and reload the software.
|
|
C17-502
|
Intermittent or hard
failure. Perform “ Create Disk Volumes” |
|
C19-304 |
Hard failure. Replace the
“P” PWB. |
|
C16-201 |
Communications with the ‘J’
PWB will usually be the cause. The problem could be
intermittent, or a hard failure. Replace the following
components until the problem is resolved: The ROS Low
Voltage Power Supply, IOT Interface Cable. If you are
experiencing C16-376 system faults, also check for a short
in the 5VDC line at the top tray empty sensor, and examine
the wiring harness above the MIM compressor. Check for any
pinched wire in the DC harness if you are also getting
C16-308 and 370 system faults also. In one incident the
Control PWB in the LVPS caused this fault, and in two
situations the PPMD PWB caused the problem; once it was a
loose connection at the Printer Card Cage. Be prepared to
camp out. |
|
F-202 |
The UI Power supply fails to
power up. Low Voltage Power Supply in the UI is bad. Before
replacing the LVPS check the fuses. I have seen several in
the field that have had cold solder joints and were actually
loose. If you have the patience, you can heat up the solder
and repair loose fuse holders. |
|
F-318 |
UI Control Board Fails at
Power UP. Try selecting “Power interrupt” and rebooting. It
may resolve your problem. If this fails, replace the UI
Control PWB. |
|
P06-250 |
For Docutech that have
“morning sickness” and the first copy produced gives this
system fault. Replace the ROS; could also get P0-6251 or
P06-359. |
|
P06-250 |
Either intermittent or hard
failure: Can be accompanied with P06-251 and/or P06-359
system faults. Check the Fuser Harness at the fuser heat
rod, and check the ground strap in the metering assembly.
Make sure the ground strap is actually touching the Metering
Roller at the bearing and is actually attached on both
sides. Check for 10 Ohms or less between the Metering Roller
and the end bearing assembly. |
|
P06-359 |
With or without P06-357
system faults. Check the Shutter PWB—it may be bad.
|
I have had many techs ask about
reprints for the articles on the repair of the Xerox 5090
(family) copier. At the present time I am compiling the
information to be published later this year. If you would like a
copy of this publication, please contact me at
VillageCopierNY@aol.com or fax me at 718-931-2488.
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